System, motor controller and associated method

ABSTRACT

An electronic control module is provided. The electronic control module is operably connected to a power supply for providing power to a motor. The electronic control module includes an input device, a processor coupled to the input device, and first and second current supply lines. The processor is configured to generate a command signal in response to an input supplied by the input device and transmit the command signal to the motor. The command signal controls an operating point of the motor. The first and second current supply lines are operably connectable to the motor and the processor. At least one of the current supply lines, the input device and the processor are adapted to utilize the current supply lines both to transmit power to the motor and to transmit the command signal to the motor over the current supply lines.

BACKGROUND OF THE INVENTION

The embodiments described herein relate generally to an electricmachine, and more specifically, to an electric motor.

An electric machine is typically in the form of an electric generator oran electric motor. The machine typically has a centrally located shaftthat rotates relative to the machine. Electrical energy applied to coilswithin the machine initiates the relative motion that transfers thepower to the shaft and, alternatively, mechanical energy from therelative motion of the generator excites electrical energy into thecoils. For expediency, the machine will be described hereinafter as amotor. It should be appreciated that a machine may operate as agenerator and vice versa.

A stationary assembly, also referred to as a stator, includes a statorcore and coils or windings positioned around portions of the statorcore. It is these coils to which energy is applied to initiate thisrelative motion which transfers the power to a rotor and then to ashaft. These coils are formed by winding wire, typically copper,aluminum or a combination thereof, about a central core to form thewinding or coil. An electric current is directed through the coils,which induces a magnetic field. It is the magnetic field that initiatesthis relative motion that transfers the power to the shaft.

Electric motors are utilized in many varied application and areenergized utilizing a user interface. The motors may be positioned inlocations not easily accessible to the user. Such applications includeceiling fans, HVAC applications and refrigeration applications. In orderto provide convenient access to the user interface, such applicationshave a user interface spaced a significant distance from the motor.

To provide improved performance and energy savings multiple speed motorsare frequently used. The user interface for such motors provides for acommand signal to be sent to the motor that include information inaddition to a simple on and off. Such signals include the properoperating speed of the multiple speed motor. The wiring harnesses neededto transmit the command signal from the user interface to the motor areexpensive to manufacture and inconvenient to install, particularly inexisting structures.

The present invention is directed to alleviate at least some of theseproblems with the prior art.

BRIEF DESCRIPTION OF THE INVENTION

The method, systems and apparatus described herein facilitate thetransmission of a command signals from a control module to an electricmachine and of responses from the electric machine to the controlmodule.

The electric machine typically includes a housing for containing andsupporting a stator that is excited by an electrical source that excitesan electromagnetic field in coils in the stator. The coils interact witha rotor rotatably supported in the housing to provide the mechanicalrotational energy for the electrical machine.

Electric machines or motors are utilized in many varied application andare energized utilizing a user interface. The motors may be positionedin locations not easily accessible to the user. Such applicationsinclude ceiling fans, HVAC applications and refrigeration applications.In order to provide convenient access to the user interface, suchapplications have a user interface spaced a significant distance fromthe motor.

To provide improved performance and energy savings multiple speed motorsare frequently used. The user interface for such motors provides for acommand signal to be sent to the motor that include information inaddition to a simple on and off. Such signals include the properoperating speed of the multiple speed motor. The wiring harnesses neededto transmit the command signal from the user interface to the motor areexpensive to manufacture and inconvenient to install, particularly inexisting structures.

According to an embodiment of the invention, an electronic controlmodule is provided. The electronic control module is operably connectedto a power supply for providing power to a motor. The electronic controlmodule includes an input device, a processor coupled to the inputdevice, and first and second current supply lines. The processor isconfigured to generate a command signal in response to an input suppliedby the input device and transmit the command signal to the motor. Thecommand signal controls an operating point of the motor. The first andsecond current supply lines are operably connectable to the motor andthe processor. At least one of the current supply lines, the inputdevice and the processor are adapted to utilize the current supply linesboth to transmit power to the motor and to transmit the command signalto the motor over the current supply lines.

According to an aspect of the present invention, the electronic controlmodule may be provided wherein the processor is configured to transmitthe command signal to a plurality of motors. The command signal controlsan operating point of each of the plurality of motors.

According to an aspect of the present invention, the electronic controlmodule may be provided wherein one of the motors includes a power supplyand may communicate with other motors on a distribution bus formed bythe supply lines.

According to an aspect of the present invention, the electronic controlmodule may be provided wherein the processor is located in the powersupply or the motor.

According to an aspect of the present invention, the electronic controlmodule may be provided wherein the processor is adapted to be programmedutilizing near field communications.

According to an aspect of the present invention, the electronic controlmodule may be provided wherein the command signal operates at, forexample, a frequency of one kilo hertz to one megahertz.

According to another embodiment of the invention, a motor control systemis provided. The system includes a motor; an input device; a processor,a current power supply; and first and second current supply lines.

According to yet another aspect of the present invention, the system maybe provided wherein the input device includes a user interface.

According to yet another aspect of the present invention, the system maybe provided wherein the user interface includes a push button switch.

According to yet another aspect of the present invention, the system maybe provided wherein the user interface includes a toggle switch.

According to yet another aspect of the present invention, the system maybe provided wherein the user interface includes a selector switch.

According to yet another aspect of the present invention, the system maybe provided wherein the selector switch is adapted to select the size ofthe room for which the system is used.

According to yet another aspect of the present invention, the system maybe provided wherein the selector switch is adapted to select the numberof air changes per day for the room for which the system is used.

The processor is coupled to the input device. The processor isconfigured to generate a command signal in response to an input suppliedby the input device and to transmit the command signal to the motor. Thecommand signal controls an operating point of the motor. The processoris operably connected to the motor.

The first and second current supply lines are operably connectable tothe motor and to the processor. At least one of the current supplylines, the input device and the processor are adapted to utilize thecurrent supply lines both to transmit power to the motor and to transmitthe command signal to the motor over the current supply lines.

According to another aspect of the present invention, the system may beprovided wherein the operating point may include the speed of the motor.

According to another aspect of the present invention, the system may beprovided wherein the operating point may include the torque applied bythe motor.

According to another aspect of the present invention, the system may beprovided wherein the operating point may include the current drawn bythe motor,

According to an aspect of the present invention, the system may furtherinclude a fan box. The power supply and/or the motor may be located inthe fan box.

According to another aspect of the present invention, the system mayfurther include a sensor,

According to another aspect of the present invention, the system may beprovided wherein the system is adapted to send a sensor signal generatedby the sensor to said processor.

According to another aspect of the present invention, the system may beprovided wherein the system is adapted to adjust the operating point inresponse to the sensor signal generated by the sensor.

According to another aspect of the present invention, the system may beprovided wherein the light sensor is adapted to determine when the roomis in use.

According to another aspect of the present invention, the system mayfurther include a timer.

According to another aspect of the present invention, the system may beprovided wherein timer cooperates with the processor to limit runtime ofthe motor.

According to another aspect of the present invention, the system may beprovided wherein timer cooperates with the processor to limit energy useof the motor.

According to another aspect of the present invention, the system may beprovided wherein timer cooperates with the processor to operate themotor to provide for a minimum number of daily air changes.

According to another aspect of the present invention, the system may beprovided wherein the sensor is an occupancy sensor.

According to another aspect of the present invention, the system may beprovided wherein the occupancy sensor includes a motion detector.

According to another aspect of the present invention, the system may beprovided wherein the motion detector includes a IR device.

According to another aspect of the present invention, the system may beprovided wherein the processor is adapted to adjust the operating speedof the motor when the occupancy sensor detects that the room isoccupied.

According to another aspect of the present invention, the system may beprovided wherein the processor is adapted to keep the motor runningafter the occupant leaves the room.

According to another aspect of the present invention, the system may beprovided wherein the processor is adapted to change the speed of themotor after the occupant leaves the room. According to another aspect ofthe present invention, the system may be provided wherein the processoris adapted to communicate with a near field communication device toconfigure the power supply.

According to another aspect of the present invention, the input devicemay include a light switch. The power supply may be located adjacent thelight switch.

According to yet another aspect of the present invention, the system maybe provided wherein the current power supply is a direct current supply.

According to yet another aspect of the present invention, the system maybe provided wherein the current power supply is a 24 Volt direct currentsupply

According to an aspect of the present invention, the system may beprovided wherein the processor is installed within the motor.

According to an aspect of the present invention, the system may beprovided wherein the processor is configured to operate the motor toprovide one of constant air flow, constant torque or constant speed.

According to an aspect of the present invention, the system may beprovided wherein the processor is configured to transmit the commandsignal to a plurality of motors. The command signal may control anoperating point of each of the plurality of motors.

According to an aspect of the present invention, the electronic controlmodule may be provided wherein one of the motors includes a power supplyand may communicate with other motors on a distribution bus formed bythe supply lines.

According to an aspect of the present invention, the system may beprovided wherein the system is adapted for use in refrigeration cabinetand wherein the processor is configured such that the operating point ofat least two of the plurality of motors are independently adjustable.

According to an aspect of the present invention, the system may beprovided wherein the processor is configured such that the operatingpoint of at least one of the plurality of motors is adjusted tocompensate for an underperforming motor.

According to an aspect of the present invention, the system may beprovided wherein the processor is configured such that the operatingpoint of at least one of the plurality of motors is adjusted to balancethe temperature of the cabinet.

According to an aspect of the present invention, the system may furtherinclude a light positioned within the cabinet. The processor may beconfigured such that the light is disabled in response to an operatingpoint of at least one of the plurality of motors.

According to an aspect of the present invention, the system may beprovided wherein the processor is located within one of the power supplyand the motor.

According to an aspect of the present invention, the system may beprovided wherein the processor is adapted to be programmed utilizingnear field communications.

According to an aspect of the present invention, the system may beprovided wherein the command signal further includes configurationparameters.

According to another embodiment of the invention, a method forcontrolling a motor is provided. The method includes the steps ofproviding first and second current supply lines, operably connecting thesupply lines to the motor and to a power supply, and receiving an inputat an electronic control module. The method further includes the stepsof generating, using the electronic control module, a command signal inresponse to the input and transmitting the command signal over the firstand second current supply lines to the motor coupled to the electroniccontrol module. The method further includes the steps of determining,from the command signal, a corresponding operating point for the motor,transmitting power from the power supply over the first and secondcurrent supply lines to the motor, and operating the motor at theoperating point.

According to another aspect of the present invention, the system may beprovided wherein the electronic control module is at least partiallylocated in the power supply.

According to another aspect of the present invention, the system may beprovided wherein the electronic control module further includes anairflow algorithm.

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to monitor speed ofthe motor,

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to monitor torque ofthe motor,

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to monitor currentdraw to the motor.

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to provide constantair flow to the system.

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to detect cloggedfilters in a HVAC system.

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to detect cloggedexhaust pipes in a ceiling fan system.

According to another aspect of the present invention, the system may beprovided wherein the airflow algorithm is adapted to send signals toindicate air flow irregularities.

According to another aspect of the present invention, the system may beprovided wherein the signals are provided by one of an LED light or ablinking light.

According to another aspect of the present invention, the system may beprovided wherein the electronic control module further includes analgorithm to monitor system health.

According to another aspect of the present invention, the system may beprovided wherein the algorithm to monitor system health includes anairflow algorithm.

According to another aspect of the present invention, the system may beprovided wherein the algorithm to monitor system health includesmonitoring for unstable variables.

According to another aspect of the present invention, the system may beprovided wherein the algorithm to monitor system health includesmonitoring for over current.

According to another aspect of the present invention, the system may beprovided wherein the algorithm to monitor system health includesmonitoring for over temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional view of an electric machine for use with anelectronic control module of the present invention;

FIG. 2 is a block diagram of an electronic control according to anembodiment of the present invention installed in the electric machine ofFIG. 1;

FIG. 3 is a block diagram of an electronic control according to anotherembodiment of the present invention showing alternate locations for theprocessor of the electronic control module;

FIG. 4 is a block diagram of the electronic control of FIG. 3 showingthe transmission of a command signal from a control module to theelectric machine and the receiving of responses from the electricmachine to the control module in greater detail;

FIG. 5 is a block diagram of the electronic control of FIG. 3 showingthe transmission of a command signal from a control module to theelectric machine and the receiving of responses from the electricmachine to the control module in greater detail;

FIG. 6 is a plan view of a ceiling fan with a wall switch utilizing anembodiment of the electronic control module of the present invention;

FIG. 7 is a plan view of a ceiling fan with a ceiling user interfaceutilizing an embodiment of the electronic control module of the presentinvention;

FIG. 8 is a plan view of a system including a plurality of motorsutilizing the electronic control module of the present invention; and

FIG. 9 is a flow chart of another embodiment of the present invention inthe form of a method for providing a system for controlling an electricmachine.

DETAILED DESCRIPTION OF THE INVENTION

The method, systems and apparatus described herein facilitate thetransmission of command signals to an electric machine.

The electric machine typically includes a housing for containing andsupporting a stator that is excited by an electrical source that excitesan electromagnetic field in coils in the stator. The coils interact witha rotor rotatably supported in the housing to provide the mechanicalrotational energy for the electrical machine.

Electric machines or motors are utilized in many varied application andare energized utilizing a user interface. The motors may be positionedin locations not easily accessible to the user. Such applicationsinclude ceiling fans, HVAC applications and refrigeration applications.In order to provide convenient access to the user interface, suchapplications have a user interface spaced a significant distance fromthe motor.

To provide improved performance and energy savings multiple speed motorsare frequently used. The user interface for such motors provides forcommand signals to be sent to the motor that include information inaddition to a simple on and off. Such signals include the properoperating speed of the multiple speed motor. The wiring harnesses neededto transmit the command signals from the user interface to the motor areexpensive to manufacture and inconvenient to install, particularly inexisting structures.

Technical effects of the methods, systems, and apparatus describedherein include at least one of reduced cost, improved serviceability,improved performance and quality and reduced labor costs.

According to an embodiment of the present invention and referring toFIG. 1, an electric machine 10 is provided. The electric machine 10 maybe an electric motor or an electric generator, but hereinafter will bedescribed as an electric motor 10. It should be appreciated that theelectric motor may be used to power any mechanism, for example, ceilingfan, a HVAC (heating, ventilation, and air conditioning) application, apump, a cyclic drive, a compressor, a vehicle, a fan or a blower.

The electric machine 10 includes a housing 12, a coil 14 operablyconnected to the housing 12 and a rotor 16. The rotor is rotatablysecured to the housing 12 and defines a first end of the housing 12. Therotor extends outwardly from a first end of the housing 12.

The electric machine or motor 10 typically includes the rotor 16 thatrotates relative to the motor 10. Electrical energy applied to typicallya plurality of coils 14 within the motor 10. The coils 14 generate anelectromagnetic field that cooperates with a magnetic field in rotor 16.The coils 14 initiate relative motion between the rotor 14 and the motor12 that transfers the power from the coils to the rotor 14.

The housing 12 may include a plurality of components and may be made ofa suitable durable material, for example a metal, a polymer or acomposite. The housing 12 may, as shown, include a cylindrical shell 18and opposed end caps 20. A shaft 22 may extend outwardly from a firstend 24 of the electric motor 10, typically extending from one of the endcaps 20. The motor 10 may have any suitable size and shape and may be,for example, an induction motor, a permanent-split capacitor (PSC)motor, an electronically commutated motor (ECM) motor, or a switchedreluctance motor. Attempts to send signals to and from a power supply ora motor controller may create additional complexity and hardware and maybe very expensive. Inexpensive and reliable transmissions of signals toand from a power supply or a motor controller is desirable in the designand manufacture of such electric machines. The method, systems andapparatus described herein facilitate transmissions of signals to andfrom a power supply or a motor controller of an electric machine.Designs and methods are provided herein to facilitate transmissions ofsignals to and from a power supply or a motor controller of an electricmachine.

According to an embodiment of the present invention and referring toFIG. 1, an electric machine 10 is provided. The electric machine 10 maybe an electric motor or an electric generator, but hereinafter will bedescribed as an electric motor 10. It should be appreciated that theelectric motor may be used to power any mechanism, for example, a pump,a cyclic drive, a compressor, a vehicle, a fan or a blower.

While as shown in FIG. 1, the electric motor 10 is an axial flux motor,a radial flux motor or any other motor configuration may be used withthis invention.

According to the present invention and referring now to FIG. 2, anelectronic control module 26 is provided. The electronic control module26 is operably connected to a power supply 28 for providing power to amotor 30. The motor 30 may be any motor and may, for example, be in theform of the motor 10 of FIG. 1.

As shown the motor 30 is an Electronically Commutated Motor (ECM) motor.ECM or EC motors are synchronous motors that are powered by a DCelectric source via an integrated inverter/switching power supply, whichproduces an AC electric signal to drive the motor. In this context, AC,alternating current, does not imply a sinusoidal waveform, but rather abi-directional current with no restriction on waveform. Additionalsensors and electronics control the inverter output amplitude andwaveform and therefore percent of DC bus usage/efficiency and frequency(i.e. rotor speed).

The rotor part of a brushless motor is often a permanent magnetsynchronous motor as described as motor 12 of FIG. 1, but can also be aswitched reluctance motor, or induction motor

In the exemplary embodiment, power supply 28 supplies a single-phasealternating current (AC) voltage to processor 34. However, power supply28 may supply three-phase AC, or any other type of input voltage thatprocessor 34 and motor 30 to function as described herein. The powersupply 28 may be a direct current power supply and may more specificallybe a 24 Volt direct current supply. Alternately, the power supply 28 maybe an alternating current (AC) power supply. If an alternate currentpower supply, the power supply may provide line voltage AC and lowvoltage AC.

The electronic control module 26 includes an input device 32; aprocessor 34 coupled to the input device 32 and first and second currentsupply lines 36 and 38, respectively.

The processor 34 is configured to generate a command signal 40 inresponse to an input 42 supplied by the input device 32 and transmit thecommand signal 40 to the motor 30. The command signal 40 controls anoperating point 44 of the motor 30. The electronic control module 26 maybe provided such that the processor 34 is adapted to be programmedutilizing near field communications. For example, the processor 34 maybe adapted to communicate with a near field communication device 3 toconfigure the power supply 28. The command signal 40 may further includeconfiguration parameters 47 for configuring the motor 30.

Further, the system 48 may be provided wherein the processor 34 isconfigured to operate the motor 30 to a constant air flow, constanttorque or constant speed. The processor 34 may provide for the operatorto select operating the system 48 with one of constant air flow,constant torque or constant speed.

The motor 30 may be any motor capable of having an operating point 44 ofthe motor controlled. For example, the motor 30 may be an electronicallycontroller motor, for example an electronically controlled motor (ECM)provided by Regal Beloit Corporation, 200 State Street, Beloit, Wis. USA

The first and second current supply lines 36 and 38, respectively, areoperably connectable to the motor 30 and the processor 34.

At least one of the current supply lines 36 and 38, the input device 32and the processor 34 are adapted to utilize the current supply lines 36and 38 both to transmit power 46 to the motor 30 and to transmit thecommand signal 40 to the motor 30 over the current supply lines 36 and38.

The input device 32 may be any device for providing operator input 42 tothe electronic control module 26. For example, the input device 32 maybe in the form of a user interface. For example, the user interface 32may in the form of a keyboard for a desktop computer, a laptop computer,or a notebook computer. For example, the user interface 32 may in theform of a smart phone. Alternately, the user interface may be adedicated combination of keys, toggles, knobs and/or other devices.Alternatively, the user interface 32 may be a selector switch or atoggle switch.

The input device 32 may transmit the input 42 in the form of a signalover hard wires or wirelessly.

The processor 34 may, as shown in FIG. 2, be positioned within theelectronic control module 26.

Alternatively, and as shown in FIG. 2, the processor may be in the formof processor 34A as shown by phantom lines. The processor 34A ispositioned within power supply 28.

Alternatively, and as shown in FIG. 2, the processor may be in the formof processor 34B as shown by dashed lines. The processor 34B ispositioned within motor 30.

It should be appreciated that the processor 34 may be alternativelypositioned elsewhere within system 48.

In accordance to the invention and as shown in FIG. 2, the input 42 issent by input device 32 to processor 34. The processor 34 sends commandsignal 40 by first current supply line 36 and by second current supplyline 38 to motor 30 to control operating point 44 of the motor 30. Theoperating point 44 may be, for example, the speed, torque, current orvoltage on the motor 30. The first current supply line 36 and the secondcurrent supply line 38 are also used to provide power 44 to the motor30. The operating point 44 may, for example, include the speed of themotor. Alternatively, the operating point 44 may include the torqueapplied by the motor 30. Alternatively, the operating point 44 mayinclude the current drawn by the motor 30.

The current supply lines 36 and 38 may be solid or stranded and may bemade of an electrically conductive metal, such as aluminum or copper.Alternately, the lines 36 and 38 may be made of a composite material,such as carbon fiber.

The use of the current supply lines 36 and 38 to convey power 44 and thecommand signal 40 can be accomplished in several ways. For example, thepower may be transmitted by direct current with a steady amplitude ofcurrent. Alternately, the power may be transmitted by alternate current.The command signal 40 may be sent by a pulse or sinusoidal current orvoltage. The pulse or sinusoidal current of the command signal 40 maythus be superimposed over the power 44 on the same lines 36 and 38. Notethat such superimposing of signals may be possible either when the poweris transmitted by alternate current or by direct current.

The electronic control module 26 may be provided such that the commandsignal 40 operates at a frequency of one kilo hertz to one megahertz.

As shown in FIG. 2 and according to another aspect of the presentinvention, the system 48 may be provided wherein the electronic controlmodule 26 further includes an airflow algorithm 39. The system 48 may beprovided wherein the airflow algorithm 39 is adapted to monitor speed ofthe motor 30. Alternatively, the system 48 may be provided wherein theairflow algorithm 39 is adapted to monitor torque of the motor 30.Alternatively, the system 48 may be provided wherein the airflowalgorithm 39 is adapted to monitor current draw to the motor 30. Itshould be appreciated that the system 48 may be provided wherein theairflow algorithm 39 is adapted to provide constant air flow to thesystem 48.

Further, the airflow algorithm 39 may be adapted to detect cloggedfilters in a HVAC system. Alternatively, the system 48 may be providedwherein the airflow algorithm 39 is adapted to detect clogged exhaustpipes in a ceiling fan system.

Alternatively, the system 48 may be provided wherein the airflowalgorithm 39 is adapted to send signals 41 to indicate air flowirregularities. For example, the system 48 may be provided wherein thesignals 41 may be provided by a signaling device 43, for example, an LEDlight or a blinking light. For example and as shown in FIG. 2, thesystem 48 may be provided wherein the airflow algorithm 39 is adapted toprovide constant air flow to the system.

According to another aspect of the present invention and as shown inFIG. 2, the system 48 may be provided wherein the electronic controlmodule further includes an algorithm 45 to monitor system health. Forexample, the system 48 may be provided wherein the algorithm 45 tomonitor system health includes the airflow algorithm 39. For example,the system 48 may be provided wherein the algorithm 45 to monitor systemhealth includes monitoring for unstable variables, monitoring for overcurrent and/or monitoring for over temperature.

According to an aspect of the present invention and referring now toFIG. 3, a system 148 may be provided. The system 148 includes anelectronic control module 126. The electronic control module 126includes an input device 132; a processor 134 coupled to the inputdevice 132 and first and second current supply lines 136 and 138,respectively.

The module 126 is similar to module 26 of FIG. 2. The module 126includes the processor 134 similar to processor 34 of module 26, exceptthat the processor 134 is positioned in or adjacent to power supply 128.The power supply 128 is similar to power supply 28 of FIG. 2.

The first and second current supply lines 136 and 138 are similar tofirst and second current supply lines 36 and 38 of FIG. 2.

The input device 132 is similar to input device 32 of FIG. 2. Similar tosystem 48 of FIG. 2, the system 148 is configured to have the inputdevice 132 send an input 142 to the processor 132. The processor 134sends a command signal or a control signal 140 over supply lines 136 and138 to motor 130. The power supply 128 sends power 146 over the supplylines 136 and 138 to motor 130. It should be appreciated that thecommand signal 140 may be changed depending on the needs of user of thesystem 148 and the command signal 140 may, over time, represent variousdifferent command signals 140.

In configuration such as those of the system 148 of FIG. 3 in which theprocessor 134 is located in the power supply 128, utilization of thesupply lines 136 and 138 to transmit both the control signal 140 and thepower 146 to the motor provides for a very simple and convenientconfiguration for the installation of the system 148 and saves in wiringmaterial costs and in wiring installation costs.

The system 148 of FIG. 3 may further provide for response signals 174from the electric motor 130 to the control module 126. Similar to thecommand signal 140, the response signals 174 may be carried over thefirst and second supply lines 136 and 138, respectively. The responsesignal 174 may provide information about the current and past conditionsin the motor and may include information obtained from sensors (notshown) in the motor or from control circuitry (not shown) within themotor that may store information including prior signals sent to themotor or received from sensors in the motor.

While the response signals 174 and the command signals 140 may beseparated from the power 146 sent to the motor 130 using any currentlyavailable technology, transmitting circuitry 176 and receiving circuity187, as shown in FIGS. 4 and 5, may be used.

As shown in FIGS. 4 and 5, the system 148 of FIG. 3 may includetransmitting circuitry 176 and receiving circuitry 178. As shown inFIGS. 4 and 5, the transmitting circuitry 176 and the receivingcircuitry 178 may be part of a system circuitry 180 located on a circuitboard 182.

A single microcontroller or microprocessor (uProcessor or uP) 184 thatmay be a part of the processor 134 located, for example, in the controlmodule 126, the power supply 128 or motor 130 will have the capabilityto transmit and receive data over the power distribution lines 136, 138(DC or AC). The transmission process begins with the uProcessor 184generating an asynchronous digital communication bit stream or signal186 at a specific BAUD rate (e.g. 4800, 9600, 19200 . . . ). This signal186 is then modulated to a higher frequency. For example, a zero statecould be represented by 180 KHz and a one state by 220 KHZ. Thisrepresent Frequency Shift Keying—in addition other encoding mechanismsare well known. The modulated signal 186 is output on one of the uP pinsas a square wave. A low cost transmission circuit 188 filters the squarewave from the uP into a waveform similar to pure sine wave. Then ananalog amplifier 190 increases the amplitude and driving power of thesignal. Finally, a passive network 192 (capacitor or capacitor/inductoror transformer) couples the modulated signal on to the powerdistribution lines on top of the existing power transmission waveform.

The receiver portion or receiving circuitry 178 of the system circuitry180 uses a passive network 194, similar to line coupling passive network192 of the transmitting portion or transmitting circuitry 176 to pullmodulated signal 195 off of the power transmission lines or power supply128 while rejecting the power carrying signal 146. An analog amplifier196 boosts the signal 195 while further filtering our high and lowfrequency noise from the power distribution system. The signal 195 isfed to a comparator 197 where the original square wave modulated signal195 is reconstructed. This square wave is fed into an input capture pin198 on the uP 184. Inside the uP 184, the frequency is detected and theoriginal asynchronous bit stream is generated. The uprocessor 184 maythen interpret the bit stream as typical with software or a standardUART hardware block 199.

According to an aspect of the present invention and referring now toFIG. 4, a system 248 may be provided. The system 248 may be configuredfor use in a bathroom 250. The system 248 includes a fan or blower 252that may be mounted in ceiling 254. The fan or blower 252 is turned offand on with a user interface or input device 232 in the form of, forexample, a wall switch mounted to wall 256 of bathroom 250. The fan 252may be positioned in a fan housing or box 235.

The system 248 includes an electronic control module 226. The electroniccontrol module 226 includes input device 232, a processor 234 coupled tothe input device 232 and first and second current supply lines 236 and238, respectively.

The module 226 is similar to module 126 of FIG. 3 in that the processor134 is positioned in or adjacent to power supply 228. The power supply228 is similar to power supply 28 of FIG. 2.

The first and second current supply lines 236 and 238 are similar tofirst and second current supply lines 36 and 38 of FIG. 2.

Similar to system 48 of FIG. 2, the system 248 is configured to have theinput device 232 send an input 242 to the processor 232. The processor234 sends a control signal 240 over supply lines 236 and 238 to motor230. The power supply 228 sends power 246 over the supply lines 236 and238 to motor 230.

In configurations such as those of the system 248 of FIG. 4 in which theprocessor 234 is located in the power supply 228, utilization of thesupply lines 236 and 238 to transmit both the control signal 240 and thepower 246 to the motor provides for a very simple and convenientconfiguration for the installation of the system 248 and saves in wiringmaterial costs and in wiring installation costs. This simple andconvenient configuration is useful for bathroom fan installations fornew construction, as well as, for repairs and bathroom remodeling. Thesupply lines 236 and 238 can be located behind walls 256 or mountedexteriorly on the walls 256 using, for example, a conduit (not shown).

According to an aspect of the present invention and referring now toFIG. 5, a system 348 may be provided. The system 348, like the system248 of FIG. 4, may be used in a bathroom 350. The system 348 includes afan or blower 352 that may be mounted in ceiling 354. The fan 352 may bemounted in a fan box 353.

In fact and as is shown in FIG. 5, the system 348 may be entirelymounted in ceiling 354. The system 348 may include a cover or door 358that may be secured, for example pivotally attached, to a system frameor housing 360 mounted in ceiling 354 and which holds or houses thecomponents of the system 348. The system frame or housing 360 may beintegral with fan box or housing 353.

The system 348 includes an electronic control module 326. The electroniccontrol module 326 includes input device 332, a processor 334 coupled tothe input device 332 and first and second current supply lines 336 and338, respectively.

The fan or blower 352 is turned off and on with user interface or inputdevice 332. The device 332 may be similar to the device 32 of the module26 of FIG. 2.

For example, the user interface 332 may in the form of a keyboard for adesktop computer, a laptop computer, or a notebook computer. Forexample, the user interface 332 may in the form of a smart phone.Alternately, the user interface may be a dedicated combination of keys,toggles, knobs and/or other devices. As shown in FIG. 5, the userinterface 332 may be a selector switch. For example, the selector switch332 may be adapted to select the size of the room for which the systemis used. Alternatively or in addition, the selector switch 332 may beadapted to select the number of air changes per day for the room forwhich the system is used.

The module 326 may be similar to module 226 of FIG. 4. The module 326may include the processor 334 similar to processor 234 of module 226.The module 326 is similar to module 226 of FIG. 4 in that the processor334 is positioned in or adjacent to power supply 328. The power supply328 is similar to power supply 28 of FIG. 2.

The first and second current supply lines 336 and 338 are similar tofirst and second current supply lines 36 and 38 of FIG. 2.

Similar to system 48 of FIG. 2, the system 348 is configured to have theinput device 332 send an input 342 to the processor 332. The processor334 sends a control signal 340 over supply lines 336 and 338 to motor330. The power supply 328 sends power 346 over the supply lines 336 and338 to motor 230.

In configuration such as those of the system 348 of FIG. 5 in which theprocessor 334 is located in the power supply 328, utilization of thesupply lines 336 and 338 to transmit both the control signal 340 and thepower 346 to the motor provides for a very simple and convenientconfiguration for the installation of the system 348 and saves in wiringmaterial costs and in wiring installation costs. This simple andconvenient configuration is useful for bathroom fan installations fornew construction, as well as, for repairs and bathroom remodeling. Thesupply lines 236 and 238 can be located within the frame 360 of thesystem 348 and be easily installed and accessed behind door 358.

The system 348 may also include a sensor 362. The sensor 362 may be usedto sense any variable, condition or characteristic that may affect theoptimum operation of the blower or fan 352. For example, the sensor 362may be used to sense light, temperature, humidity or motion. The systemmay be provided wherein the system is adapted to send a sensor signal364 generated by the sensor 362 to the processor 334. The sensor signal364 may be the input 342 or may be an additional signal and may betransmitted to the processor 334 in any suitable manner, such as thosemanners described regarding the transmission of input 42.

It should be appreciated that the system 348 may be provided wherein thesystem 348 is adapted to adjust the operating point 344 in response tothe sensor signal 364 generated by the sensor 362.

The system 348 may be provided wherein the system 348 is adapted toadjust an operating point 344 of the motor 340 in response to the sensorsignal 364 generated by the sensor 362.

The sensor may be any sensor capable measuring any variable, conditionor characteristic such as light, temperature, humidity or motion. Forexample, the sensor 362 may be a light sensor. The light sensor 362 maybe adapted to determine when the room 350 is in use.

According to another aspect of the present invention and as shown inFIG. 5, the system 348 may be provided wherein the sensor 362 is anoccupancy sensor. The occupancy sensor 362 may, for example, be in theform of a motion detector. The motion detector 362 may be in the form ofa IR device.

According to another aspect of the present invention and as shown inFIG. 5, the system 348 may be provided wherein the processor 334 isadapted to adjust the operating speed of the motor 330 when theoccupancy sensor 362 detects that the room 350 is occupied.

According to another aspect of the present invention and as shown inFIG. 5, the system 348 may be provided wherein the processor 334 isadapted to keep the motor 330 running after the occupant leaves the room350.

According to another aspect of the present invention and as shown inFIG. 5, the system 348 may be provided wherein the processor 334 isadapted to change the speed of the motor 330 after the occupant leavesthe room 350.

As shown in FIG. 5, the system 348 may further include a timer 364. Forexample, the timer 364 may cooperate with the processor 334 to limitruntime of the motor 330. Alternatively or in addition, the timer 364may cooperate with the processor 334 to limit energy use of the motor330. Alternatively or in addition, the timer 364 may cooperate with theprocessor 334 to operate the motor 330 to provide for a minimum numberof daily air changes.

According to an aspect of the present invention and referring now toFIG. 6, an electronic control module 426 is shown for use in system 448.The system 448 includes the module 426 including a processor 434configured to transmit a command signal 440 to a plurality of motors430. The command signal 430 controls an operating point 444 of each ofthe plurality of motors 430. The processor 434 sends a control signal440 over supply lines 436 and 438 to motors 430. The power supply 428sends power 446 over the supply lines 436 and 438 to motor 430.

The system 448 may be adapted for use in refrigeration cabinet 470. Theprocessor 434 may be configured such that the operating point 444 of atleast two of the plurality of motors 430 is independently adjustable.Further, the processor 434 may be configured such that the operatingpoint 444 of at least one of the plurality of motors 430 is adjusted tocompensate for an underperforming motor. Further, the system 448 may beprovided wherein the processor 434 is configured such that the operatingpoint 444 of at least one of the plurality of motors 430 is adjusted tobalance the temperature of the cabinet 470. Further, the system 448 mayfurther include a light 472 positioned within the cabinet 470. Theprocessor 434 may be configured such that the light 472 is disabled inresponse to an operating point 444 of at least one of the plurality ofmotors 430.

Continuing to refer to FIG. 6, one motor 430A of the motors 430 mayinclude power supply 428A and may communicate with other motors 430 B,430C, and 430D on a distribution bus 484 formed by the supply lines 436and 438.

According to another embodiment of the invention, a method 500 forcontrolling a motor is provided. The method 500 includes step 510 ofproviding first and second current supply lines, step 512 of operablyconnecting the supply lines to the motor and to a power supply, and step514 of receiving an input at an electronic control module. The methodfurther includes step 516 of generating, using the electronic controlmodule, a command signal in response to the input and step 518 oftransmitting the command signal over the first and second current supplylines to the motor coupled to the electronic control module. The methodfurther includes step 520 of determining, from the command signal, acorresponding operating point for the motor, step 522 of transmittingpower from the power supply over the first and second current supplylines to the motor, and step 524 of operating the motor at the operatingpoint.

The methods, systems, and apparatus described herein facilitateefficient and economical assembly of an electric machine. Exemplaryembodiments of methods, systems, and apparatus are described and/orillustrated herein in detail. The methods, systems, and apparatus arenot limited to the specific embodiments described herein, but rather,components of each apparatus and system, as well as steps of eachmethod, may be utilized independently and separately from othercomponents and steps described herein. Each component, and each methodstep, can also be used in combination with other components and/ormethod steps.

When introducing elements/components/etc. of the methods and apparatusdescribed and/or illustrated herein, the articles “a”, “an”, “the”, and“the” are intended to mean that there are one or more of theelement(s)/component(s)/etc. The terms “comprising”, “including”, and“having” are intended to be inclusive and mean that there may beadditional element(s)/component(s)/etc. other than the listedelement(s)/component(s)/etc.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

Described herein are exemplary methods, systems and apparatus utilizinglower cost materials in a permanent magnet machine that reduces oreliminates the efficiency loss caused by the lower cost material.Furthermore, the exemplary methods system and apparatus achieveincreased efficiency while reducing or eliminating an increase of thelength of the machine. The methods, system and apparatus describedherein may be used in any suitable application. However, they areparticularly suited for HVAC and pump applications.

Exemplary embodiments of the fluid flow device and system are describedabove in detail. The electric machine and its components are not limitedto the specific embodiments described herein, but rather, components ofthe systems may be utilized independently and separately from othercomponents described herein. For example, the components may also beused in combination with other machine systems, methods, andapparatuses, and are not limited to practice with only the systems andapparatus as described herein. Rather, the exemplary embodiments can beimplemented and utilized in connection with many other applications.

Although specific features of various embodiments of the disclosure maybe shown in some drawings and not in others, this is for convenienceonly. In accordance with the principles of the disclosure, any featureof a drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

1. An electronic control module operably connected to a power supply forproviding power to a motor, said electronic control module comprising:an input device; a processor coupled to said input device, saidprocessor configured to: generate a command signal in response to aninput supplied by said input device; transmit the command signal to themotor, wherein the command signal controls an operating point of themotor; generate a response signal from the motor; and transmit theresponse signal to the processor; and first and second current supplylines operably connectable to the motor and said processor, at least oneof said current supply lines, said input device and said processor beingadapted to utilize said current supply lines both to transmit power tothe motor and to transmit said command signal to the motor and saidresponse signal from the motor over said current supply lines.
 2. Anelectronic control module in accordance with claim 1: wherein saidprocessor is configured to transmit the command signal to a plurality ofmotors; and wherein the command signal controls an operating point ofeach of the plurality of motors.
 3. An electronic control module inaccordance with claim 1, wherein said processor is located within one ofthe power supply and the motor.
 4. An electronic control module inaccordance with claim 1, wherein said processor is adapted to beprogrammed utilizing near field communications.
 5. An electronic controlmodule in accordance with claim 1, wherein the command signal operatesat a frequency of one kilo hertz to one megahertz.
 6. A motor controlsystem comprising: a motor; an input device; a processor coupled to saidinput device, said processor configured to: generate a command signal inresponse to an input supplied by said input device; transmit the commandsignal to the motor, wherein the command signal controls an operatingpoint of the motor; operably connected to the motor; generate a responsesignal from the motor; and transmit a response signal from the motor tothe processor; a current power supply; and first and second currentsupply lines operably connectable to said motor and said processor, atleast one of said current supply lines, said input device and saidprocessor being adapted to utilize said current supply lines both totransmit power to said motor and to transmit the command signals to saidmotor and the response signal from the motor over said current supplylines.
 7. The system in accordance with claim 6: further comprising afan box; and wherein at least one of said power supply and said motorare housed in said fan box.
 8. The system in accordance with claim 6:wherein said input device includes a light switch; and wherein saidpower supply is located adjacent said light switch.
 9. The system inaccordance with claim 6, wherein said current power supply is a 24 Voltdirect current supply.
 10. The system in accordance with claim 6,wherein said processor is installed within said motor.
 11. The system inaccordance with claim 6, wherein said processor is configured to operatesaid motor to provide one of constant air flow, constant torque andconstant speed.
 12. The system in accordance with claim 12, wherein saidprocessor is configured to transmit the command signal to a plurality ofmotors, wherein the command signal controls an operating point of eachof the plurality of motors.
 13. The system in accordance with claim 11:wherein the system is adapted for use in a refrigeration cabinet; andwherein said processor is configured such that the operating point of atleast two of said plurality of motors are independently adjustable. 14.The system in accordance with claim 13, wherein said processor isconfigured such that the operating point of at least one of saidplurality of motors is adjusted to compensate for an underperformingmotor.
 15. The system in accordance with claim 13, wherein saidprocessor is configured such that the operating point of at least one ofsaid plurality of motors is adjusted to balance the temperature of saidcabinet.
 16. The system in accordance with claim 13: further comprisinga light positioned within said cabinet; and wherein said processor isconfigured such that said light is disabled in response to an operatingpoint of at least one of said plurality of motors.
 17. The system inaccordance with claim 6, wherein said processor is located within one ofsaid power supply and said motor.
 18. The system in accordance withclaim 6, wherein said processor is adapted to be programmed utilizingnear field communications.
 19. The system in accordance with claim 6,wherein the command signal further includes configuration parameters.20. A method for controlling a motor, said method comprising: providingfirst and second current supply lines; operably connecting the supplylines to the motor and to a power supply; receiving an input at anelectronic control module; generating, using the electronic controlmodule, a command signal in response to the input; transmitting thecommand signal over the first and second current supply lines to themotor coupled to the electronic control module; generating, using theelectronic control module, a response signal from the motor;transmitting the response signal from the motor over one of the firstand second current supply lines to the processor; determining, from thecommand signal, a corresponding operating point for the motor;transmitting power from the power supply over the first and secondcurrent supply lines to the motor; and operating the motor at theoperating point.
 21. An electronic control module in accordance withclaim 1, wherein said processor modulates the command signal into amodulated command signal and wherein said processor modulates theresponse signal into a modulated response signal.
 22. The system inaccordance with claim 6, further comprising: transmitting circuitry fortransmitting the command signal; and receiving circuitry fortransmitting the response signal.